Cheese having reintroduced fine particles of cheese

ABSTRACT

Methods of making acid and rennet-based cheeses include processing a previous lot of milk to produce curds and whey from the previous lot of milk, and removing the whey from the curd. For cottage cheeses, curds are washed with a wash water. Whey and wash water (when used) include fine particles of curd, which are collected, added, and mixed into a subsequent lot of milk preferably using a mixer such as a homogenizer or colloid mill. Mixing preferably reduces the fine particle size of at least a plurality of the fine particles and increases the total amount of surface area thereof. Fine particles are reincorporated into the matrix of the curd made from the subsequent lot of milk, which increases curd yield. Also provided is a higher yield cheese that is made from a subsequent lot of milk that includes fine particles of curd from a previous lot of milk.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.10/074,870, filed Feb. 13, 2002, which is incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The invention relates to methods of making cheese, and, in particular,methods of making cheese that have an increased yield of cheese curd.

DESCRIPTION OF THE RELATED ART

The main ingredient used in making cheese is milk. Ninety percent ofmilk produced in Wisconsin goes into the cheese-making process. Thereare two types of techniques for processing milk into curds and whey:acid precipitation and rennet precipitation. In acid precipitation, anacid-forming microorganism or an acid is added to the milk. For example,a specific bacteria that is capable of digesting lactose into lacticacid is added to the milk. As the pH of the milk reaches the isoelectricpoint of casein, the casein forms a continuous clot or curd. Acid-basedcheeses include cottage cheese, cream cheese, and Ricotta cheese. Inrennet precipitation, rennet is added to warm milk (at about 30-35° C.),causing the casein to form curd. Rennet-based cheeses include cheesessuch as mozzarella, Cheddar, Swiss, and colby cheese.

Curd is fragile. It has long been known that handling it causes is todegrade into fine particles of curd, oftentimes referred to as “fines”or “cheese fines.” Fine particles result from, e.g., cutting andstirring the curds. Additionally, pumping the curd to the drain tableand draining the curd at the drain table also generates fine particles.Furthermore, when curds from, e.g., cottage cheese, are cooled andwashed, fine particles flow away with cooling and wash water.

Generation of fine particles during a cheese-making process is known tobe highly undesirable for several reasons. First, degradation causes asignificant percentage of the curd to be lost. That is, fine particlesdo not contribute to cheese yield. Second, it has become environmentallyunacceptable and even unlawful in some jurisdictions to discharge curdfines into the sewerage system. In jurisdictions that permit dischargeof fine particles into the sewerage system, the high biological oxygendemand (BOD) of these particles and whey presents disposal problems.When whey that includes fine particles is discharged into a seweragesystem, a BOD cost is added for its disposal. At least part of the BODcost is assessed based on the amount of fine particles present in thewhey. To reduce the disposal cost for the whey, many cheese makersremove fine particles from whey before it is discharged. Fine particlescan be removed with a fine saver, such as a vibrating sieve. Fineparticles are then disposed of separately.

Many cheese makers truck the whey, wash water, and fines into thecountry where it is distributed over large land areas at a high cost orfed to animals. Additionally, whey has such a high BOD that it can killfresh water fish and the plants and other animals that live in theenvironment into which the whey is disposed. In sum, fine particles arecostly to dispose of and contribute to pollution and environmentaldamage.

For every 100 pounds of milk processed into cheese, about 0.4 pounds offine particles of cheese are generated. The United States produced 8.3billion pounds of renneted cheese in the year 2000. Thus, cheese yieldscould have been significantly higher had fine particles not been lost.As noted above, the loss of fine particles reduces the amount offinished cheese available for sale and represents a loss in the overallyield in the cheese making process. In rennet-based cheeses, attemptshave been made to put fine particles back into the cheese-makingprocess. For example, some cheese makers put collected fines back ontothe drain table on top of curd. However, the vast majority of fineparticles are subsequently lost because the fine particles do notincorporate themselves into the matrix of the curd.

In view of the foregoing, it would be desirable to provide a method ofrecovering fine particles of cheese from a previous lot of milk andreincorporating the recovered fine particles into a subsequent cheesemilk for increasing yield during the cheese making process. It wouldalso be desirable to provide a cheese that includes fine particlesrecovered from a previous lot of cheese milk, thereby producing a cheesehaving a higher yield of curd.

SUMMARY OF THE INVENTION

The invention, which is defined by the claims set out at the end of thisdisclosure, is intended to solve at least some of the problems notedabove. Methods of making two different classes of cheese are provided.The method begins by processing a previous lot of milk to produce cheesecurds and whey. Whey is removed from the cheese curds. Whey includesfine particles of cheese curd. Additionally, wash water, which is usedwhen making, e.g., cottage cheese, includes fine particles of cheesecurd. Fine particles of cheese curd are collected from the whey and thenadded to a subsequent lot of milk. Where wash water is used, fineparticles of cheese curd can also be collected therefrom. In a preferredembodiment, the fine particles from the previous lot of milk are mixedinto the subsequent lot of milk. Mixing preferably includes at leastpartially solubilizing fine particles of cheese curd from the previouslot of milk into the subsequent lot of milk. It also preferably includesmaintaining fine particles in solution by inhibiting or even preventingfine particles from settling out of the subsequent lot of milk.

In a preferred embodiment, a homogenizer or colloid mill is used to mixfine particles of cheese curd into the subsequent lot of milk.Homogenizers are standard equipment in dairy factories for makingacid-based cheeses, such as cottage cheese. In another preferredembodiment, a colloid mill is used to mix fine particles of cheese curdinto the subsequent lot of milk. Fine particles can be added to aportion or the entire lot of the subsequent milk. The methodadvantageously is versatile in that it can be used to make bothacid-based cheeses and rennet-based cheeses.

Fine particles of cheese curd, having been reduced in size byhomogenization or passing through a colloid mill, are reincorporatedinto the matrix of the cheese curd made from the subsequent lot of milk,thereby increasing the yield of cheese curd made from the subsequent lotof milk. In a preferred embodiment, virtually all fine particlesrecovered from a previous lot of milk are incorporated into cheese curdmade from the subsequent lot of milk.

Also provided is a cheese that includes fine particles of cheese curdfrom a previous lot of milk and cheese curd that is processed from asubsequent lot of milk. Fine particles of cheese curd from the previouslot of milk are incorporated into the matrix of the cheese curd from thesubsequent lot of milk. Acid-based cheeses and rennet-based cheeseshaving an increased yield of curd are provided.

In addition, a method of making a dressing is provided. The methodincludes processing a lot of milk to produce cheese curds and whey. Thecheese curds are removed from the whey and wash water, which includesfine particles of cheese curd. The fine particles of cheese curd arethen collected and added to a mixture including salt, cultured flavor,milk, and a stabilizer to form the dressing. Additionally, a dressing isprovided that includes fine particles of cheese curd isolated from aprevious lot of milk, salt, cultured flavor, cream, milk, and astabilizer.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred exemplary embodiments of the invention are illustrated in theaccompanying drawing, in which:

FIG. 1A is a flowchart showing steps for making rennet-based cheeses ina preferred embodiment of carrying out the invention.

FIG. 1B is a flowchart showing steps for making acid-based cheeses in apreferred embodiment of carrying out the invention.

FIG. 2A is a schematic of a portion of the equipment for practicing atleast one preferred embodiment of the invention.

FIG. 2B is a schematic of a portion of the equipment for practicing atleast one other preferred embodiment of the invention.

FIG. 2C is a schematic of a portion of the equipment for practicinganother preferred embodiment of the invention.

FIG. 3 is a flowchart showing steps in a first preferred method ofcarrying out the invention.

FIG. 4 is a flowchart showing steps in a second preferred method ofcarrying out the invention.

FIG. 5 is a flowchart showing steps in a third preferred method ofcarrying out the invention.

FIG. 6 is a cross-sectional view of a colloid mill used in some of thepreferred equipment arrangements.

Before explaining embodiments of the invention in detail, it is to beunderstood that the invention is not limited in its application to thedetails of construction and the arrangement of the components set forthin the following description or illustrated in the drawings. Theinvention is capable of other embodiments or being practiced or carriedout in various ways. Also, it is to be understood that the phraseologyand terminology employed herein is for the purpose of description andshould not be regarded as limiting.

DETAILED DESCRIPTION

1. General Overview of the Invention

A method of making cheese that produces a higher yield than conventionalmethods is provided. Referring to FIG. 1A, which shows a preferredembodiment of the invention for rennet-based cheeses, a previous lot ofmilk is processed with rennet to produce cheese curd and whey. It shouldbe noted that the term processed is interchangeably used herein with theterms clotted, coagulated, and curdled. The whey is removed from thecheese curd. The whey contains fine particles of cheese curd. Fineparticles are collected from the whey. Collected fine particles areadded to a subsequent lot of milk. The invention provides severaloptions for where the fine particles can be added during thecheese-making process. Representative options are discussed in detailbelow.

As used herein, the terms previous and subsequent refer both tocontinuous flow processes and batch processes. Additionally, the termlot refers to both to continuous flow processes and batch processes.

Further processing of the rennet curd after the removal of the wheytypically includes adding cheese salt to control acid development.However, some cheese is salt brined following the molding or following ahooping. Once the cheese has been salted and molded, it is allowed toripen. This can take anywhere from two weeks to several months or evenlonger, depending upon the type of cheese being made. During the curingprocess, bacteria digest, e.g., the casein, fats, and lactose. Thevariety of cheese produced will depend on the types of bacteria, thecuring times, and the temperature and humidity of the storeroom.

Fine particles collected from the whey from the previous lot of milk aremixed in the subsequent lot of milk. The subsequent lot of milk isprocessed into cheese. The mixing permits fine particles from a previouslot of milk to be incorporated into the matrix of the curd formed fromthe subsequent milk lot. Mixing preferably is performed withoutrequiring demineralization, namely decalcification, of the fineparticles. A significantly higher yield of cheese results from thesubsequent lot of milk due to the presence of fine particles from theprevious lot of milk.

The fine particles are mixed into the subsequent lot of milk preferablyusing a mixer, such as a homogenizer, a colloid mill, or the like. Themixer is set at an appropriate setting such that passage of the fineparticles through the mixer causes at least one of the followingeffects: reduction in particle size of at least a plurality of theparticles, increase in surface area allowing for increasedsolubilization, reduction of the effect of gravity on the particlesbecause now they have reduced size, maintenance of fine particles insolution by inhibiting or preventing them from settling out from thecheese milk, and at least partially dissolving protein and trappedminerals in fine particles. Where the homogenizer is of two-stageconstruction, the homogenizer preferably operates at a setting ofbetween about 500 and about 3500 psi, and more preferably at about 2000psi. When using a colloid mill, it is preferably operated at a settingsuch that is has a clearance of about 0.01 inches to about 0.04 inches,and more preferably about 0.01 inches. Additionally, the inherent pH ofthe milk buffers the acidity of fine particles and at least partiallysolubilizes fine particles in the milk.

FIG. 1B shows a preferred embodiment of the invention for acid-basedcheeses in which milk is processed with an acid to produce curds andwhey. For acid-based cheeses, milk typically is acidified either bydirect addition of an acid or by adding a bacterial inoculum, such asLactococcus lactis ssp lactis or Lactococcus lactis ssp cremoris, whichproduces lactic acid via lactose digestion. The pH of the milk decreasesuntil it reaches the isoelectric point of casein, typically a pH of 4.6,causing a clot to occur.

FIG. 1B varies from FIG. 1A in that optional steps of washing the curdswith a wash water and collecting fine particles from the wash water areincluded. This washing step is typically used when making cottagecheese. Where washing is performed, the curd is usually washed multipletimes, typically three times, with cold water to further remove residualwhey and reduce the curd temperature. Wash water also contains fineparticles of cheese curd. Where curds are washed in any of the followingmethods, it is to be understood that fine particles can be collectedfrom the wash water and be used in a subsequent lot of milk.

Several preferred equipment arrangements and preferred methods forcarrying out the invention will now be described in detail.

2. Fine Particles from Acid-Based Cheese Reintroduced at Balance Tank

Attention is now directed to FIGS. 2A and 3. FIG. 2A shows a preferredequipment arrangement for making acid-based cheese with the invention.FIG. 3 illustrates steps for performing a first preferred method. Cheesemilk, i.e., the milk from which cheese is made, is admitted to apasteurization system 20 from a balance tank 22. The milk is transferredfrom the balance tank 22 through a conduit 24 to a regenerator 26 of thepasteurization system 20. Milk typically enters the regenerator at about40° F. (40° C.). Initially, milk is preheated in the regenerator 26. Theregenerator 26, which basically is a heat exchanger, permits incomingmilk, which typically is raw or unpasteurized, to scavenge excess heatfrom outgoing, heat-treated milk and thereby provides preheating for theincoming milk and pre-cooling to the outgoing milk. Milk typically exitsthe regenerator 26 at about 150° F. (66° C.).

Milk exits the regenerator 26 through a conduit 28 and can enter aseparator 30, which separates cream from the milk and transports thecream to a cream storage 32 via a cream line 34. The separator 30typically includes a bowl (not shown) that contains conical plates (notshown) that are stacked about an inner perimeter (not shown) of the bowlof the separator 30. The separator bowl (not shown) rotates on a spindle(not shown) at about 6,000 rpm or at a speed that produces an equivalentG force. At this speed, all dense, fine material is displaced toward anouter perimeter of the bowl. Fine particles that are present in milkcollect at an outer perimeter of the bowl. When this happens, it can beimpractical, if not impossible, to salvage fine particles andreincorporate them into a subsequent milk lot. To avoid this, theseparator 30 can be bypassed when admitted cheese milk is already at adesired fat content. For example, when making cottage cheese, theseparator can be bypassed if the admitted cheese milk is already at adesired fat content, such as separated to less than 0.1% fat. By-passvalves 36, 38 may be provided in conduits 28, 40 leading to and from theseparator 30 in order to permit valving out, i.e., bypassing, theseparator 30 via conduit 41.

A homogenizer 42, which renders milk more homogenous, is locateddownstream from the separator 30. Milk flowing out of the homogenizer 42travels via conduit 44 to a heater 46. The milk is heated to apasteurization temperature of around 163° F. (73° C.) by the heater 46,typically using heat from a steam-energized hot water supply. Afterbeing heated in the heater 46, the milk is passed to a holding tube 48,where the milk is retained at an elevated temperature for apredetermined time to reduce the amount of bacteria present in the milk.

The pasteurized milk then returns via conduit 51 to the regenerator 26where it transfers heat to the incoming milk of a subsequent lot,causing its own temperature to drop. After passing through theregenerator 26, the pasteurized milk flows through conduit 49 to acooler 50 to further lower its temperature, typically to about 35° F.(about 1-2° C.).

After chilling, the pasteurized milk is transferred through conduit 52to a cheese vat 55, where, for acid-based cheeses, the milk is processedinto curds and whey with an acid. The curd is then cut into cubes of apredetermined size, depending on the style of cheese being made. Forexample, when making cottage cheese, the curd is cut into cubes having aspecific size, depending upon whether small curd or large curd cottagecheese is being made.

The cubes of curd are allowed to settle and heal for a period of time.The curd is then agitated and cooked very slowly, e.g., to a temperatureof about 130° F. (54° C.) for cottage cheese. The agitation and cookingexpels whey from the curd. The curd is moved, e.g., with a pump (notshown) through conduit 56 to a drain table 58, where the whey is removedfrom the curd during draining. Whey removed from the curd contains fineparticles of curd. If desired, curds can be washed with a wash water.

The whey is transferred, such as through a conduit 60, to a fine saver62, which preferably is a vibrating sieve, to collect fine particles ofcurd. A preferred fine saver 62 is a Sweeco Vibrating Screen, which isavailable from Sweeco, Inc. of Florence, Ky. Other devices, such as arotating belt for separating fine particles or a revolving drum or otherdevice, can also be used to separate fine particles of cheese curd fromwhey.

Where washing is performed, fine particles can also be collected fromthe wash water. The wash water is transferred to the fine saver 62,where fine particles are collected. These fine particles can also beused in a subsequent lot of milk.

For acid curd, such as cottage cheese and similar cheeses, furtherprocessing of the curd typically includes adding a cream dressing to thecurd and blending by gentle stirring. The dressing includes, forexample, about two-thirds of the finished cottage cheese and containssalt, cultured flavor, enough milk and cream to satisfy label needs, anda stablizer. Containers are then filled, sealed, and followed byrefrigeration.

Full fat, low fat, and no fat cottage cheese dressings typically requirethe addition of non-fat dry milk solids during manufacture. For this,fines collected from whey from previous lots of milk are used to buildneeded solids in cottage cheese dressings. Such dressings preferably arepasteurized and homogenized, and thus, meet the pasteurization processas outlined in FIGS. 2A and 2B.

In this preferred embodiment, fine particles of cheese curd recoveredfrom this previous lot of milk are added into a subsequent lot of cheesemilk at or near the balance tank 22 (as indicated by conduit 63 in FIG.2A). The subsequent lot of milk, including recovered fine particles fromthe previous lot of milk, moves from the balance tank 22 to theregenerator 26 via conduit 24. From the regenerator 26, the subsequentlot of milk, including the recovered fine particles, preferably isdiverted around the separator 30. The diversion is preferablyaccomplished by closing the valves 36 and 38 to divert the subsequentlot of milk, including the recovered fine particles, through conduits28, 41, and 40, thereby bypassing the separator 30. This avoids theaforementioned problem related to fine particles separating out ofsolution onto the outer perimeter of the bowl of the separator 30. Withthe separator 30 valve out, the subsequent lot of milk and the fineparticles travel from the regenerator 26 to the homogenizer 42.

At the homogenizer 42, the recovered fine particles are mixed into thesubsequent lot of milk. Preferably, the homogenized milk and recoveredfine particles mixture then travels through conduit 44 to the heater 46,where the mixture is then subsequently pasteurized in the holding tube48. Thus, fine particles are pasteurized an additional time. The mixturethen continues through the cheese making equipment described above.

This preferred embodiment, in which the milk is diverted around theseparator, is particularly useful when the cheese milk entering from thebalance tank 22 already has the needed amount of fat. In this case, noseparation of the cream from the milk is necessary. For example, this isparticularly useful when making skim milk cheese and skim milk is in thebalance tank.

3. Fine Particles from Acid-Based Cheese Reintroduced Prior toHomogenization

Still referring to FIG. 2A and now also referring now to FIG. 4, in asecond preferred method, which is particularly useful for makingacid-based cheeses, such as cottage cheeses, fine particles from thewhey of a previous lot of milk are added into a subsequent lot of milkcheese at conduit 40 (as indicated by conduit 65 shown in phantom inFIG. 2A), after the milk passes through the separator 30 and before themilk enters the homogenizer 42. At the homogenizer 42, fine particlesare mixed into the subsequent lot of milk, as in the first preferredmethod. Adding recovered fine particles after the milk passes throughthe separator 30 avoids the aforementioned problem of generatingunsalvageable fine particles inside of the separator 30. Additionally,as in the first preferred method, additional pasteurization of recoveredfine particles occurs. One of the benefits of the second preferredmethod is that the cheese milk can be of a different fat level than thecheese that is produced therefrom. For example, using this preferredembodiment, high fat milk enters the separator 30, where the cream isremoved to produce lower or nonfat milk. Fine particles are added to thereduced fat milk downstream of the separator 30 at, e.g., conduit 40.Preferably, fine particles are added into the subsequent lot of milk ator upstream of the homogenizer 42 after the fat content of the milk islowered in the separator 30. Thus, a cheese can be produced that has alower fat content than would be made if the milk had not been separatedand had full fat content.

4. Fine Particles from Acid-Based Cheese Reintroduced After thePasteurizer

Attention is now directed to FIGS. 2B and 5, which shows steps for athird preferred method, which is particularly useful for makingacid-based cheeses. FIG. 2B shows a preferred equipment arrangement thatis similar to that shown in FIG. 2A except for the inclusion of acolloid mill 54, which is located upstream of the cheese vat 55. In thepreferred equipment arrangement shown in FIG. 2B, the colloid mill 54 islocated upstream of the cheese vat 55 and downstream of the cooler 50. Acolloid mill 54 provides flexibility in that it can be added to thecheese-making equipment at a variety of places, with the conduit 52being a preferred location. The colloid mill 54 is used to mix the fineparticles and the subsequent lot of milk.

Referring to FIG. 6, a typical colloid mill 54 includes an inlet 56 andan outlet 58, and a high-velocity rotating inner drum 60 and a staticouter drum 62. A passageway 64 between the inner and outer drums 60, 62preferably is adjusted to 0.01 inch wide. On their opposing surfaces,the inner and outer drums 60, 62 include longitudinally extendinggrooves (not shown). The grooves are on the order of {fraction(1/16)}^(th) of an inch deep, and preferably each have a sidewall thatis disposed at an angle of 90° relative to the passageway 64 between thedrums 60, 62. The angled sidewalls provide a shearing edge that reducesthe size of the fine particles moving through the colloid mill 54.

Preferably, the milk and fine particles enters the colloid mill 54 atthe inlet 56 and moves into the passageway 64 between the revolving andstatic drums 60, 62, respectively. During operation, relative rotationbetween the inner drum 60 and the outer drum 62 shears fine particlespassing through the passageway 64. This advantageously makes themsmaller, which, in turn, makes it easier for them to more fullysolubilize. Apart from solubilization, smaller fine particles are easierto maintain in suspension and are therefore more easily incorporatedinto the matrix of the cheese curd. The milk and recovered fineparticles exits the colloid mill 54 via the outlet 58.

In this preferred method, recovered fine particles from a previous lotof milk are added into a subsequent lot of milk cheese at conduit 52 (asindicated by conduit 67 in FIG. 2B), downstream from the cooler 50 andupstream from the colloid mill 54, where the fine particles and milk aremixed. In this preferred embodiment, unless fine particles from theprevious lot of milk are re-pasteurized separately from the subsequentlot of milk, no re-pasteurization of fine particles occurs. In thispreferred embodiment, the separator 30 may or may not be bypassed,depending on whether a reduction in the fat content of the cheese milkis desired.

5. Fine Particles from Rennet-Based Cheese Reintroduced at Balance Tank

Referring to FIG. 2C, in a fourth preferred embodiment, which isparticularly useful for rennet-based cheeses, fine particles from thewhey from a previous lot of milk are added to a subsequent lot of milkcheese via conduit 40 (indicated by conduit 69 in FIG. 2C) at thebalance tank 22.

The equipment arrangement of FIG. 2C replaces the homogenizer 42 with acolloid mill 54. This equipment arrangement, i.e., the inclusion of acolloid mill 54, can be used when the cheese making facility lacks ahomogenizer, such as is typically the case for a cheese-making facilitywhere only rennet-based cheeses are made. Although FIG. 2C shows thecolloid mill 54 being located downstream of the fine saver 62 and theseparator 30 and upstream of the heater 46, the colloid mill 54 can beplaced at other locations if desired. A colloid mill 54 can also be usedto mix the fine particles where it is impractical to use a homogenizer54 to add cheese fines as feedstock to the homogenizer. Where it isdesired also to use a homogenizer and colloid mill together, the colloidmill 54 can be located upstream of the homogenizer.

Also of note is that the arrangement of equipment of the FIG. 2C omits acooler. Hence, cheese milk may go directly from the regenerator 26 tothe cheese vat 55 via conduit 49, which is continuous with conduit 52.In this arrangement, conduit 51, which leads from the holding tube 48,branches into two separate conduits 51′ and 51″, with one of theconduits 51′ being connected to the regenerator 26 and the other one ofthe conduits 51″ being connected to conduit 52 by a temperaturecontrolled valve 53. In this instance, milk exiting the regenerator 26may be blended with milk from conduit 51″ at the valve 53. The additionof milk from the holding tube 48, and the absence of running the milkthrough a cooler, permits milk to be directed to the cheese vat 55 at ahigher temperature of, for example, 72° F. (22° C.), which is measuredat a temperature sensor 57. As with acid-based curd, rennet curd isdrained at the drain table 58 after the milk is processed with rennet atthe cheese vat.

6. Fine Particles from Rennet-Based Cheese Reintroduced Prior to ColloidMill

Still referring to FIG. 2C, in a fifth preferred method, which isparticularly useful for rennet-based cheeses, fine particles from thewhey from a previous lot of milk are added to a subsequent lot of milkcheese at conduit 40 (indicated by conduit 71 shown in phantom in FIG.2C) upstream of the colloid mill 54.

In this preferred method, unless fine particles from the previous lot ofmilk are re-pasteurized separately from the subsequent lot of milk, nore-pasteurization of fine particles occurs. In this preferred method, ifdesired, the cheese milk can be run through the separator 30 becausefine particles are added subsequent to the milk being separated in theseparator 30 and with the colloid mill 54 inline or feeding into conduit40 from a blending tank (not shown) containing milk of the correct fatcontent and fine particles from the previous lot of milk.

7. Conclusion

Using a method described herein, fine particles, which traditionallywere considered a waste product, are recovered and added back into thecheese making process. When making any type of cheese using anypreferred method described herein, virtually all of the fine particlesthat are collected from a previous lot of milk cheese preferably can beadded and mixed into a subsequent lot of milk. About 0.4 pounds of fineparticles are generated for each 100 pounds of milk processed. Thus,from 25,000 pounds of milk, 100 pounds of fine particles are produced.Using a method described herein, for 25,000 pounds of cheese milk, 100pounds of fine particles can be recovered. The recovered 100 pounds offine particles can be added and mixed into a subsequent 25,000 pound lotof cheese milk. While the subsequent 25,000 pounds of milk will againproduce and lose 100 pounds of fine particles, there is virtually a zeroloss of fine particles for each subsequent lot of cheese milk, because100 pounds of fine particles from the previous lot of milk were added tothe subsequent lot of milk. Furthermore, even if fine particles are lostan additional time, they will be recovered again when the next lot ofmilk is processed.

Adding and mixing fine particles of curd collected from a previous lotof cheese milk into a subsequent lot of cheese milk increases the yieldof cheese produced. Using a method described herein, fine particles froma previous lot of cheese milk are reincorporated into the matrix of thecurd made from a subsequent lot of milk. This results in virtually allrecovered fine particles contributing to the increase in curd yield froma subsequent lot of milk. For example, using traditional methods, theyield of curd is approximately 14 pounds of cottage cheese curd for 100pounds of fluid skim milk. Recovering and reincorporating fine particlesinto a subsequent lot of cheese milk increases the yield of curd betweenby at least 2%, and preferably between about 2.5% and about 3.0%.

Using a method described herein to recover and use fine particlesrepresents a financial savings for cheese makers. For every 25,000pounds of milk, which generates 100 pounds of fine particles, using thecurrent cost for cottage cheese fine particles ($1.00 per pound), amethod described herein would currently produce a savings of $100 forevery 25,000 pounds of cheese milk that is processed into cottagecheese. For Cheddar cheese, the per-pound price of fine particles ishigher ($1.60/pound) than for cottage cheese. A savings of $160 isrealized for every 25,000 pounds of milk that is processed into Cheddarcheese.

In the United States in 1999, 722 million pounds of cottage cheese and2,816,867,000 pounds of Cheddar cheese were produced. Using a methoddescribed herein, an additional 2.9 million pounds higher yield ofcottage cheese and an additional 11.3 million pounds higher yield ofCheddar cheese would have resulted. Thus, for cottage cheese alone,recovering and reincorporating fine particles back into the cheese curdwould result in a $2.9 million value based on the 1999 data. For Cheddarcheese alone, based on the 1999 data, recovering and reincorporatingfine particles back into the cheese curd would produce a $18.1 millionvalue.

Additionally, using a method described herein, disposal costs for fineparticles are dramatically reduced or even eliminated. Thus, pollutioncaused by fine particles is reduced or even eliminated. The costsassociated with disposing of fine particles is also dramatically reducedor even eliminated. The disposal cost of whey and/or fine particlesthemselves is also reduced because whey produced in the inventivemethod, which has had fine particles removed, is a lower-BOD effluent.Thus, the biological oxygen demand cost is reduced.

Furthermore, the method described herein is cost effective in terms ofequipment necessary to practice the invention. The preferred equipmentarrangements that use a homogenizer can be practiced using standardequipment already available in cheese plants that make, e.g., acid-basedcheeses. The preferred embodiments that use a colloid mill can bepracticed with relatively little financial investment: currently around$16,000 for a colloid mill. Additionally, fine savers are standardequipment in virtually all cheese plants.

Preferably, recovered fine particles are added into the next lot ofmilk, with recovered fine particles remaining out of the cheese-makingprocess as little time as possible. This minimizes bacteriologicalproblems associated with holding fines at a temperature at whichundesired microorganisms can grow. If the addition of fine particles isdelayed, fine particles can be refrigerated preferably at less than 45°F. (7° C.) until they are used. Additionally, it is preferred to usefine particles when they are as fresh as possible because continueddevelopment of acidity in fine particles does not enhance theirreincorporation into a subsequent lot of milk cheese. Most cheese plantsrun 24 hours a day, 6-7 days a week. Thus, using a method describedherein, except for the last lot of cheese milk run through a plant,virtually no measurable loss of fine particles occurs during thecheese-making process.

Cottage cheese made with the method described herein was evaluated andtaste tested and was advantageously found to be organolepticallyindistinguishable from cottage cheese made with traditional methods.Thus, the quality of cottage cheese made with the inventive method wasnot altered.

It is understood that the various preferred embodiments are shown anddescribed above to illustrate different possible features of theinvention and the varying ways in which these features may be combined.Apart from combining the different features of the above embodiments invarying ways, other modifications are also considered to be within thescope of the invention. The invention is not intended to be limited tothe preferred embodiments described above, but rather is intended to belimited only by the claims set out below. Thus, the inventionencompasses all alternate embodiments that fall literally orequivalently within the scope of these claims.

1. A cheese, comprising: (a) fine particles of cheese curd from aprevious lot of milk; and (b) cheese curd that is processed from asubsequent lot of milk, wherein the fine particles of cheese curd fromthe previous lot of milk are incorporated into the matrix of the cheesecurd of the subsequent lot of milk.
 2. A cheese of claim 1, wherein thefine particles of cheese curd are incorporated at a ratio of about 0.4pounds of the fine particles per 100 pounds of milk.
 3. A cheese ofclaim 1, wherein the cheese curd is processed from acidified milk.
 4. Acheese of claim 3, wherein the cheese comprises cottage cheese.
 5. Acheese of claim 1, wherein the cheese curd is processed fromrennet-treated milk.
 6. A cheese of claim 5, wherein the cheese isselected from the group consisting of Cheddar, mozzarella, Swiss, andcolby cheeses.
 7. A cheese of claim 6, wherein the fine particles ofcheese curd that are incorporated into the matrix of the cheese curd ofthe subsequent lot of milk have a size that is reduced.
 8. A cheese,comprising: (a) fine particles of cheese curd collected from a washwater used to wash cheese curd from a previous lot of milk; and (b)cheese curd that is processed from a subsequent lot of milk.
 9. A cheeseof claim 8, wherein the fine particles of cheese curd are notdemineralized.
 10. A cheese, comprising: (a) fine particles of cheesecurd collected from cheese curd made from a previous lot of milk,wherein the fine particles of cheese curd are not demineralized; and (b)cheese curd that is processed from a subsequent lot of milk.
 11. Acheese of claim 10, wherein the fine particles of cheese curd are notdecalcified.
 12. A cheese, comprising: (a) fine particles of cheese curdcollected from cheese curd made from a previous lot of milk, wherein thecollected fine particles of cheese curd are integrated into a subsequentlot of milk and have a total surface area that is increased whencompared to fine particles of cheese curd that have not been integratedinto the subsequent lot of milk; and (b) cheese curd that is processedfrom the subsequent lot of milk.
 13. A cheese of claim 12, wherein thefine particles of cheese curd are at least partially solubilized intothe subsequent lot of milk.
 14. A cheese of claim 12, wherein the cheesecurd is processed from acidified milk.
 15. A cheese of claim 12, whereinthe cheese curd is processed from rennet-treated milk.
 16. A cheese ofclaim 12, wherein the cheese is selected from the group consisting ofCheddar, mozzarella, Swiss, and colby cheeses.